Recent advances in surface engineering of additive manufactured materials for enhancing corrosion resistance

Additive manufacturing processes have gained popularity for their ability to create complex geometries, but they often introduce unique challenges in terms of material properties and surface quality. The corrosion performance of additive manufactured (AM) materials is a complex topic influenced by multiple factors. Corrosion resistance is a significant parameter for industries like aerospace, automotive, and biomedical, where the reliability and durability of components are critical. Surface engineering poses several challenges for enhancing the corrosion resistance of AM materials such as microstructural heterogeneity, material selection, post-processing effects, localized corrosion susceptibility etc. The aim of this paper is to examine the corrosion behavior of the additive manufactured metals, alloys, polymers, and composites. Further, recent research on the surface engineering on these materials to enhance the corrosion resistance are also reviewed. According to the reported studies, surface alteration of AM metals and alloys by ultrasonic acid etching, plasma, thermal, and laser treatment showed excellent corrosion resistance. Different coatings such as copper, and nickel on AM polymers provided superior corrosion protection. Moreover, modification of the AM composite surface by sol–gel process or thermal treatment improved the corrosion resistance. However, future innovations offer promising avenues for improvement in corrosion resistance of AM materials. Modifying materials specifically for AM processes, employing advanced coating technologies, and integrating in situ monitoring during manufacturing are possibilities for corrosion resistance enhancement. The development of corrosion-resistant nanomaterials, novel surface modification techniques, and the integration of computational modeling into the design process hold potential for overcoming the challenges and propelling the field toward enhanced corrosion-resistant additive manufactured materials.